SUPERtrol II Flow Computer

Transcription

1 SUPERtrol II Flow Computer Third Edition KESSLER-ELLIS PRODUCTS 10 Industrial Way East Eatontown, NJ Fax: /25/11

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3 CONTENTS SAFETY INSTRUCTIONS INTRODUCTION 1.1 Unit Description Specifications INSTALLATION 2.1 General Mounting Hints Mounting Diagrams APPLICATIONS 3.1 Steam Mass Steam Heat Steam Net Heat Steam Delta Heat Corrected Gas Volume Gas Mass Gas Combustion Heat Corrected Liquid Volume Liquid Mass Liquid Combustion Heat Liquid Sensible Heat Liquid Delta Heat Steam Condensate Heat WIRING 4.1 Terminal Designations Typical Wiring Connections Flow Input Stacked DP Input Pressure Input Temperature Input Temperature 2 Input Wiring In Hazardous Areas Flow Input Pressure Input Temperature Input UNIT OPERATION 5.1 Front Panel Operation Concept for Operate Mode General Operation Password Protection Relay Operation Pulse Output Analog Outputs Function Keys; Display Grouping RS-232 Serial Port Operation PC Communications Operation of RS-232 Serial Port with Printers RS-485 Serial Port Operation Pause Computations Prompt PROGRAMMING 6.1 Front Panel Operation Concept for Program Mode EZ Setup Detailed Menu Descriptions System Parameters Display System Units Fluid Data Flow Input Other Input Pulse Output Current Output Relays Communication Network Card Service & Analysis...86

4 CONTENTS 7. PRINCIPLE OF OPERATION 7.1 General Square Law Flowmeter Considerations Flow Equations Flow Input Computation Pressure Computation Temperature Computation Density/Viscosity Computation Corrected Volume Flow Computation Mass Flow Computation Combustion Heat Flow Computation Heat Flow Computation Sensible Heat Flow Computation Liquid Delta Heat Computation Expansion Factor Computation for Square Law Flowmeters Uncompensated Flow Computation ILVA Flow Meter Equations Computation of the D.P. Factor RS-232 SERIAL PORT 8.1 RS-232 Serial Port Description Instrument Setup by PC Over Serial Port Operation of Serial Communication Port with Printers ST2 RS-232 Port Pinout RS-485 SERIAL PORT 9.1 RS-485 Serial Port Description General Operation of Serial Communication Port with PC ST2 RS-485 Port Pinout FLOW COMPUTER SETUP SOFTWARE 10.1 System Requirements Cable and Wiring Requirements Installation for Windows 3.1 or Using the Flow Computer Setup Software File Tab Setup Tab View Tab Misc. Tab GLOSSARY OF TERMS 10 Glossary Of Terms Diagnosis and Troubleshooting 12.1 Response of ST2 on Error or Alarm Diagnosis Flowchart and Troubleshooting Error Messages Appendix A Fluid Properties Table Appendix B - Setup Menus Setup Menus with Operator Code Access Setup Menus with Supervisor Code Access Appendix C - RS-485 Modbus Protocol Description Wiring Pinout and Installation Register and Coil Usage Warranty Decoding Part Number...121

5 SAFETY INSTRUCTIONS! The following instructions must be observed. This instrument was designed and is checked in accordance with regulations in force EN ( Safety of information technology equipment, including electrical business equipment ). A hazardous situation may occur if this instrument is not used for its intended purpose or is used incorrectly. Please note operating instructions provided in this manual. The instrument must be installed, operated and maintained by personnel who have been properly trained. Personnel must read and understand this manual prior to installation and operation of the instrument. The manufacturer assumes no liability for damage caused by incorrect use of the instrument or for modifications or changes made to the instrument. Technical Improvements The manufacturer reserves the right to modify technical data without prior notice. 1

6 1. Introduction 1.1 Unit Description: The SUPERtrol II (ST2) Flow Computer satisfies the instrument requirements for a variety of flowmeter types in liquid, gas, steam and heat applications. Multiple flow equations are available in a single instrument with many advanced features. The alphanumeric display offers measured parameters in easy to understand format. Manual access to measurements and display scrolling is supported. The versatility of the Flow Computer permits a wide measure of applications within the instrument package. The various hardware inputs and outputs can be soft assigned to meet a variety of common application needs. The user soft selects the usage of each input/output while configuring the instrument. The isolated analog output can be chosen to follow the volume flow, corrected volume flow, mass flow, heat flow, temperature, pressure, or density by means of a menu selection. Most hardware features are assignable by this method. The user can assign the standard RS-232 Serial Port for data logging, or transaction printing, or for connection to a modem for remote meter reading. A PC Compatible software program is available which permits the user to rapidly redefine the instrument configuration. Language translation option features also permit the user to define his own messages, labels, and operator prompts. These features may be utilized at the OEM level to creatively customize the unit for an application or alternately to provide for foreign language translations. Both English and a second language reside within the unit. NX-19 option Advanced ordering options are available for Natural Gas calculations where the user requires compensation for compressibility effects. Compensation for these compressibility effects are required at medium to high pressure and are a function of the gas specific gravity, % CO2, % Nitrogen, as well as temperature and pressure. The compressibility algorithm used is that for NX-19. Stacked differential pressure transmitter option This option permits the use of a low range and high range DP transmitter on a single primary element to improve flow transducer and measurement accuracy. Peak demand option This option permits the determination of an hourly averaged flow rate. Demand last hour, peak demand and time/date stamping for applications involving premium billing. Data logging option This option provides data storage information in 64k of battery backed RAM. Items to be logged, conditions to initiate the log and a variety of utilities to clear and access the data via the RS-232 port are provided. Peak Demand Option There are applications where customer charges are determined in part by the highest hourly averaged flowrate observed during a billing period. The peak demand option for the ST2 is intended for applications where it is important to compute such an hourly average flowrate, to note the value of the peak occurrence and the corresponding time and date of that event. The demand last hour rate is computed based on the current total and the total 60 minutes prior. This value is recomputed every 5 minutes. The peak demand is the highest value observed in the demand last hour. The time and date stamp is the time and date at which the highest peak demand occurred. The Demand Last Hour and/or Peak Demand can be directly viewed on the display by pressing the RATE key and then scrolling through the rates with the ^/v arrow key until the desired item is viewed. The Peak Time and Date stamp can be viewed on the display by pressing the TIME and then scrolling through the time related parameters using the ^/v arrow keys until the desired item is viewed. All of these items can be included into the scrolling display list along with the other process values and totalizers in a user selectable list. The peak demand may be cleared by pressing the CLEAR key while viewing the PEAK DEMAND or by means of a command on the serial port. The Peak Time and Date stamp can be viewed on the display by pressing the TIME and then scrolling through the time related parameters using the ^/v arrow keys until the desired item is viewed. The Demand Last Hour and Peak Demand can be assigned to one of the analog outputs. The demand last hour or peak demand could thusly be output on a recording device such as a strip chart recorder or fed into a building energy automation system. The Demand Last Hour and Peak Demand can be assigned to one of the relays. The customer can be notified that he is approaching or exceeding a contract high limit by assigning the demand last hour to one of the relays and setting the warning point into the set point. A warning message would also be displayed. The peak demand may be used in conjunction with the print list and data logger to keep track of hourly customer usage profiles. The Demand Last Hour, Peak Demand, and Time and Date Stamp information can be accessed over the serial ports. The Peak Demand may also be reset over the serial ports. The peak demand option may also be used as a condition to call out in remote metering by modem. EZ Setup The unit has a special EZ setup feature where the user is guided through a minimum number of steps to rapidly configure the instrument for the intended use. The EZ setup prepares a series of questions based on flow equation, fluid, and flowmeter type desired in the application. 2

7 1.2 Specifications: Environmental Operating Temperature: 0 to +50 C Storage Temperature: -40 to +85 C Humidity : 0-95% Non-condensing Materials: UL, CSA, VDE approved Approvals: CE Approved Light Industrial, UL/CSA Pending Display Type: 2 lines of 20 characters Types: Backlit LCD and VFD ordering options Character Size: 0.3" nominal User selectable label descriptors and units of measure Keypad Keypad Type: Membrane Keypad Keypad Rating: Sealed to Nema 4 Number of keys: 16 Raised Key Embossing Enclosure Enclosure Options: Panel, Wall, Explosion Proof Size: See Chapter 2; Installation Depth behind panel: 6.5" including mating connector Type: DIN Materials: Plastic, UL94V-0, Flame retardant Bezel: Textured per matt finish Equipment Labels: Model, safety, and user wiring NX-19 Compressibility Calculations Temperature -40 to 240 F Pressure 0 to 5000 psi Specific Gravity to 1.0 Mole % CO2 0 to 15% Mole % Nitrogen 0 to 15% Power Input The factory equipped power options are internally fused. An internal line to line filter capacitor is provided for added transient suppression. MOV protection for surge transient is also supported Universal AC Power Option: 85 to 276 Vrms, 50/60 Hz Fuse: Time Delay Fuse, 250V, 500mA DC Power Option: 24 VDC (16 to 48 VDC) Fuse: Time Delay Fuse, 250V, 1.5A Transient Suppression: 1000 V Flow Inputs: Flowmeter Types Supported: Linear: Vortex, Turbine, Positive Displacement, Magnetic, GilFlo, GilFlo 16 point, ILVA 16 Point, Mass Flow and others Square Law: Orifice, Venturi, Nozzle, V-Cone, Wedge, Averaging Pitot, Target, Verabar, Accelabar and others Multi-Point Linearization: May be used with all flowmeter types. Including: 16 point, UVC and dynamic compensation. 3 Analog Input: Ranges Voltage: 0-10 VDC, 0-5 VDC, 1-5 VDC Current: 4-20 ma, 0-20 ma Basic Measurement Resolution: 16 bit Update Rate: 2 updates/sec minimum Accuracy: 0.02% FS Automatic Fault detection: Signal over/under-range, Current Loop Broken Calibration: Operator assisted learn mode. Learns Zero and Full Scale of each range Fault Protection: Fast Transient: 1000 V Protection (capacitive clamp) Reverse Polarity: No ill effects Over-Voltage Limit: protection Over-Current Protection: 5 0 V D C O v e r v o l t a g e Internally current limited protected to 24 VDC Optional: Stacked DP transmitter 0-20 ma or 4-20 ma Pulse Inputs: Number of Flow Inputs: one Input Impedance: 10 kω nominal Trigger Level: (menu selectable) High Level Input Logic On: 2 to 30 VDC Logic Off: 0 to.9 VDC Low Level Input (mag pickup) Selectable sensitivity: 10 mv and 100 mv Minimum Count Speed: 0.25 Hz Maximum Count Speed: Selectable: 0 to 40 khz Overvoltage Protection: 50 VDC Fast Transient: Protected to 1000 VDC (capacitive clamp) Temperature, Pressure, Density Inputs The compensation inputs usage are menu selectable for temperature, temperature 2, pressure, density, steam trap monitor or not used. Calibration: Operator assisted learn mode Operation: Ratiometric Accuracy: 0.02% FS Thermal Drift: Less than 100 ppm/c Basic Measurement Resolution: 16 bit Update Rate: 2 updates/sec minimum Automatic Fault detection: Signal Over-range/under-range Current Loop Broken RTD short RTD open Transient Protection: 1000 V (capacitive clamp) Reverse Polarity: No ill effects Over-Voltage Limit (Voltage Input): 50 VDC Over-Current Limit (Internally limited to protect input to 24 VDC) Available Input Ranges (Temperature / Pressure / Density / Trap Monitor) Current: 4-20 ma, 0-20 ma Resistance: 100 Ohms DIN RTD 100 Ohm DIN RTD (DIN , BS 1904): Three Wire Lead Compensation Internal RTD linearization learns ice point resistance 1 ma Excitation current with reverse polarity protection Temperature Resolution: 0.1 C Temperature Accuracy: 0.5 C

8 Datalogger (optional) Type: Battery Backed RAM Size: 64k Initiate: Key, Interval or Time of Day Items Included: Selectable List Data Format: Printer or CSV Access via RS-232 command Stored Information (ROM) Steam Tables (saturated & superheated), General Fluid Properties, Properties of Water, Properties of Air, Natural Gas User Entered Stored Information (EEPROM / Nonvolatile RAM) Transmitter Ranges, Signal Types Fluid Properties (specific gravity, expansion factor, specific heat, viscosity, isentropic exponent, combustion heating value, Z factor, Relative Humidity) Units Selections (English/Metric) RS-232 Communication Uses: Printing, Setup, Modem, Datalogging Baud Rates: 300, 1200, 2400, 9600 Parity: None, Odd, Even Device ID: 0 to 99 Protocol: Proprietary, Contact factory for more information Chassis Connector Style: DB 9 Female connector Power Output: 8V (150 ma max.) provided to Modem RS-485 Communication (optional) Uses: Network Communications Baud Rates: 300, 600, 1200, 2400, 4800, 9600, Parity: None, Odd, Even Device ID: 1 to 247 Protocol: ModBus RTU Chassis Connector Style: DB 9 Female connector (standard) Excitation Voltage ma overcurrent protected Relay Outputs The relay outputs usage is menu assignable to (Individually for each relay) Hi/Lo Flow Rate Alarm, Hi/Lo Temperature Alarm, Hi/Lo Pressure Alarm, Pulse Output (pulse options), Wet Steam or General purpose warning (security). (Peak demand and demand last hour optional) Number of relays: 2 (3 optional) Contact Style: Form C contacts (Form A with 3 relay option) Contact Ratings: 240 V, 1 amp Fast Transient Threshold: 2000 V Analog Outputs The analog output usage is menu assignable to correspond to the Heat Rate, Uncompensated Volume Rate, Corrected Volume Rate, Mass Rate, Temperature, Density, or Pressure. (Peak demand and demand last hour optional) Number of Outputs: 2 Type: Isolated Current Sourcing (shared common) Isolated I/P/C: 500 V Available Ranges: 0-20 ma, 4-20 ma (menu selectable) Resolution: 16 bit Accuracy: 0.05% FS at 20 Degrees C Update Rate: 5 updates/sec Temperature Drift: Less than 200 ppm/c Maximum Load: 1000 ohms Compliance Effect: Less than.05% Span 60 Hz rejection: 40 db minimum EMI: No effect at 10 V/M Calibration: Operator assisted Learn Mode Averaging: User entry of DSP Averaging constant to cause an smooth control action Isolated Pulse output The isolated pulse output is menu assignable to Uncompensated Volume Total, Compensated Volume Total, Heat Total or Mass Total. Isolation I/O/P: 500 V Pulse Output Form (menu selectable): Open Collector NPN or 24 VDC voltage pulse Nominal On Voltage: 24 VDC Maximum Sink Current: 25 ma Maximum Source Current: 25 ma Maximum Off Voltage: 30 VDC Saturation Voltage: 0.4 VDC Pulse Duration: User selectable Pulse output buffer: 8 bit Real Time Clock The Flow Computer is equipped with either a super cap or a battery backed real time clock with display of time and date. Format: 24 hour format for time Day, Month, Year format for date Daylight Savings Time (optional) Measurement The Flow Computer can be thought of as making a series of measurements of flow, temperature/density and pressure sensors and then performing calculations to arrive at a result(s) which is then updated periodically on the display. The analog outputs, the pulse output, and the alarm relays are also updated. The cycle then repeats itself. Step 1: Update the measurements of input signals- Raw Input Measurements are made at each input using equations based on input signal type selected. The system notes the out of range input signal as an alarm condition. Step 2: Compute the Flowing Fluid Parameters- The temperature, pressure, viscosity and density equations are computed as needed based on the flow equation and input usage selected by the user. 4

9 Step 3 : Compute the Volumetric Flow- Volumetric flow is the term given to the flow in volume units. The value is computed based on the flowmeter input type selected and augmented by any performance enhancing linearization that has been specified by the user. Step 4: Compute the Corrected Volume Flow at Reference Conditions- In the case of a corrected liquid or gas volume flow calculation, the corrected volume flow is computed as required by the selected compensation equation. Step 5 : Compute the Mass Flow- All required information is now available to compute the mass flow rate as volume flow times density. A heat flow computation is also made if required. Step 6: Check Flow Alarms- The flow alarm functions have been assigned to one of the above flow rates during the setup of the instrument. A comparison is now made by comparing the current flow rates against the specified hi and low limits. Step 7: Compute the Analog Output- This designated flow rate value is now used to compute the analog output. Step 8: Compute the Flow Totals by Summation- A flow total increment is computed for each flow rate. This increment is computed by multiplying the respective flow rate by a time base scaler and then summing. The totalizer format also includes provisions for total rollover. Step 9: Pulse Output Service- The pulse output is next updated by scaling the total increment which has just been determined by the pulse output scaler and summing it to any residual pulse output amount. Step 10: Update Display and Printer Output- The instrument finally runs a task to update the various table entries associated with the front panel display and serial outputs. Instrument Setup The setup is password protected by means of a numeric lock out code established by the user. The help line and units of measure prompts assure easy entry of parameters. An EZ Setup function is supported to rapidly configure the instrument for first time use. A software program is also available which runs on a PC using a RS-232 Serial for connection to the Flow Computer. Illustrative examples may be down loaded in this manner. The standard setup menu has numerous subgrouping of parameters needed for flow calculations. There is a well conceived hierarchy to the setup parameter list. Selections made at the beginning of the setup automatically affect offerings further down in the lists, minimizing the number of questions asked of the user. In the setup menu, the flow computer activates the correct setup variables based on the instrument configuration, the flow equation, and the hardware selections made for the compensation transmitter type, the flow transmitter type, and meter enhancements (linearization) options selected. All required setup parameters are enabled. All setup parameters not required are suppressed. Also note that in the menu are parameter selections which have preassigned industry standard values. The unit will assume these values unless they are modified by the user. Most of the process input variables have available a default or emergency value which must be entered. These are the values that the unit assumes when a malfunction is determined to have occurred on the corresponding input. It is possible to enter in a nominal constant value for temperature or density, or pressure inputs by placing the desired nominal value into the default values and selecting "manual". This is also a convenience when performing bench top tests without simulators. The system also provides a minimum implementation of an audit trail which tracks significant setup changes to the unit. This feature is increasingly being found of benefit to users or simply required by Weights and Measurement Officials in systems used in commerce, trade, or custody transfer applications. Simulation and Self Checking: This mode provides a number of specialized utilities required for factory calibration, instrument checkout on start-up, and periodic calibration documentation. A service password is required to gain access to this specialized mode of operation. Normally quality, calibration, and maintenance personnel will find this mode of operation very useful. Many of these tests may be used during start-up of a new system. Output signals may be exercised to verify the electrical interconnects before the entire system is put on line. The following action items may be performed in the Diagnostic Mode: Print Calibration/Maintenance Report View Signal Input (Voltage, Current, Resistance, Frequency) Examine Audit Trail Perform a Self Test Perform a Service Test View Error History Perform Pulse Output Checkout / Simulation Perform Relay Output Checkout / Simulation Perform Analog Output Checkout / Simulation Calibrate Analog Inputs using the Learn Feature Calibrate Analog Output using the Learn Feature Schedule Next Maintenance Date Note that a calibration of the analog input/output will advance the audit trail counters since it effects the accuracy of the system. 5

10 Operation of Steam Trap Monitor In applications on Saturated Steam, the otherwise unused Compensation Input may be connected to a steam trap monitor that offers the following compatible output signal levels: 4mA = trap cold 12 ma = trap warm and open (blowing) 20 ma = trap warm and closed In normal operation a steam trap is warm and periodically opens and closes in response to the accumulation of condensate. A cold trap is indication that it is not purging the condensate, a trap that is constantly blowing is an indication that it is stuck open. To avoid a false alarm, the ST2 permits the user to program a delay, or time period, which should be considered normal for the trap to be either cold, or open. An alarm will only be activated if the trap is detected as continuously being in the abnormal states for a time period greater than this TRAP ERROR DELAY time. The user selects to use the Compensation Input for Trap Monitoring by selecting 4-20mA TRAP STATUS as the INPUT SIGNAL for OTHER INPUT1. The user can program the ERROR DELAY time in HH:MM format into both the TRAP ERROR DELAY (cold trap error) menu and the TRAP BLOWING DELAY (trap stuck open) menu. The ST2 will warn the operator of a TRAP ERROR when an abnormal condition is detected. The error can be acknowledged by pressing the ENTER key. However, the problem may reassert itself if there is a continued problem with the steam trap. In addition, the event is noted in the ERROR LOG. It is also possible for the user to program a trap malfunction as one of the conditions worthy of a CALL OUT of a problem by selecting this error in the ERROR MASK. The Data-Logging option of the ST2 can also be used to log the performance of the trap by storing the % of time the trap has been cold, and/or blowing open during the datalog interval. Datalogging Option The Datalogging Option for the ST2 permits the user to automatically store sets of data items as a record on a periodic basis. A datalog record may be stored as the result of either a PRINT key depression, or an INTERVAL, or a TIME OF DAY request for a datalog. The user defines the list of items to be included in each datalog by selecting these in the PRINT LIST menu located within the COMMUNICATIONS SUBMENU. The user selects what will trigger a datalog record being stored in the PRINT INITIATE menu. The choices are PRINT KEY, INTERVAL, and TIME OF DAY. The user can also define whether he just wants the data stored into the datalogger, or if he wants the data both stored in the datalogger and sent out over the RS232 port in the DATALOG ONLY menu. The user can define the format he wishes the data to be output in using the DATALOG FORMAT menu. Choices are PRINTER and DATABASE. PRINTER format will output the data records in a form suitable to dump to a printer. DATABASE format will output the values in a CSV, or Comma Separated Variable with Carriage return delimiting of each record. A number of serial commands are also included to access and manipulate information stored with in the datalogger. Among these RS232 command capabilities are the following actions: Clear Data Logger Send all Data in Datalogger Send Only New Data since Datalogger was last Read Send Data for the date included in the request Send the column heading text for the CSV data fields Send the column units of measure text for the CSV data fields Store one new record into datalogger now Read Number of New Records in the datalogger Read number of records currently in the datalogger Read the maximum number of records capacity of the datalogger Move Pointer Back N records Dump Record at Pointer Dump records newer than pointer Dump data from N records back The datalogger option is used in conjunction with the RS-232 port in remote metering applications. The technical details associated with the serial commands are listed in Universal Serial Protocol Manual available upon request. RS-232 Serial Port The Flow Computer has a general purpose RS-232 Port which may be used for any one of the following purposes: Transaction Printing Data Logging Remote Metering by Modem Computer Communication Link Configuration by Computer Print System Setup Print Calibration/Malfunction History Instrument Setup by PC s over Serial Port A Diskette program is provided with the Flow Computer that enables the user to rapidly configure the Flow Computer using an Personnel Computer. Included on the diskette are common instrument applications which may be used as a starting point for your application. This permits the user to have an excellent starting point and helps speed the user through the instrument setup. The user can select the datalog store interval in a HH:MM format in the PRINT INTERVAL menu. The user can also select the store time of day in a 24 hr HH: MM format in the PRINT TIME menu. 6

11 Operation of Serial Communication Port with Printers The Flow Computer s RS-232 channel supports a number of operating modes. One of these modes is intended to support operation with a printer in metering applications requiring transaction printing, data logging and/or printing of calibration and maintenance reports. For transaction printing, the user defines the items to be included in the printed document. The user can also select what initiates the transaction print generated as part of the setup of the instrument. The transaction document may be initiated via a front panel key depression. In data logging, the user defines the items to be included in each data log as a print list. The user can also select when or how often he wishes a data log to be made. This is done during the setup of the instrument as either a time of day or as a time interval between logging. The system setup and maintenance report list all the instrument setup parameters and usage for the current instrument configuration. In addition, the Audit trail information is presented as well as a status report listing any observed malfunctions which have not been corrected. The user initiates the printing of this report at a designated point in the menu by pressing the print key on the front panel. Operating Serial Communication Port with Modems The ST2 offers a number of capabilities that facilitate its use with modems. The ST2 s RS232 port can be connected to a modem in order to implement a remote metering system that uses either the phone companies standard phone lines or cellular telephone system. In addition to remote meter readings, the serial commands may also be used to examine and/or make setup changes to the unit, and to check for proper operation or investigate problems. Several hundred commands are supported. A compatible industrial modem accessory and interconnecting cabling is offered in the MPP2400N specifically designed for use with the ST2. The ST2 and Modem can be used together to create systems with one or more of the following capabilities: 1. Poll the ST2 unit for information from a remote PC. 2. Call Out from the ST2 unit to a remote PC on a scheduled reading time and/or crisis basis 3. Some combination of the above two descriptions where the unit is polled by one PC and calls into to a different PC if a problem is detected. In fact, up to five ST2 units can share the same modem. Each ST2 must have a unique DEVICE ID. This multidropping of flow computers on a single modem is popular when there are several flow computers mounted near each other. In most applications using modem communications, the ST2 s RS232 USAGE is first set equal to MODEM. Each ST2 on a shared modem cable is given a unique serial device address or DEVICE ID. The BAUD RATE is commonly set to 2400, the PARITY set to NONE, and the HANSHAKING set to NONE to complete the basic setup. The remote PC s communication settings are chosen to match these. The level of complexity of the Supetrol-2 to Modem connection can range from simple to more complex. In a simple system a remote PC will call into the telephone number of the modem. The modem will answer the call, and establish a connection between the ST2 and the remote PC. An exchange of information can now occur. The ST2 will act as a slave and respond to commands and requests for information from the remote MASTER PC. The MASTER PC will end the exchange by handing up. However, it is more common that the ST2 will be used to control the modem. In these applications the following communication menu settings would be used: RS232 USAGE = MODEM DEVICE ID, BAUD RATE, PARITY, and HANDSHAKING are set MODEM CONTROL = YES DEVICE MASTER = YES (When multidropping several ST2's, only one unit will be the DEVICE MASTER) MODEM AUTO ANSWER = YES (This instructs the unit to answer incoming calls) HANG UP IF INACTIVE = YES (This instructs the unit to hang up the line if no activities occur within several minutes). A more complex form of a remote metering system can be implemented where the ST2 will initiate a call to contact the remote PC at a scheduled time and/or in the event of a problem that has been detected. In these applications the ST2 has additional setup capabilities including: The ST2 must have a unique identifier assigned to it (using the TAG NUMBER) Call Out Telephone number must be entered in the CALL OUT NUMBER The scheduled call out time for the daily reading must be entered in CALL OUT TIME A decision must be made whether the unit will be used to call on error(s) in CALL ON ERROR The particular error conditions to call out on must be defined in the ERROR MASK The NUMBER OF REDIALS to be attempted if line is busy must be entered in that cell HANG UP IF INACTIVE= YES will disconnect the call if remote computer does not respond. Consult the Universal Serial Commands User Manual for details on the individual commands supported by the ST2. Contact the Flow Applications Group for a discussion on the remote metering system capabilities you are considering. NOTE: Some modems can be configured in advance to answer incoming calls, terminate phone connections if communications is lost. In such applications there may be no need for the ST2 to be functioning to control the modem. Setting the RS233 USAGE = COMPUTER will likely work. RS-485 Serial Port (optional) The RS-485 serial port can be used for accessing flow rate, total, pressure, temperature, density and alarm status information. The port can also be used for changing presets and acknowledging alarms. 7

12 2. Installation General Mounting Hints 2.1 General Mounting Hints: The ST2 Flow Computer should be located in an area with a clean, dry atmosphere which is relatively free of shock and vibration. The unit is installed in a 5.43" (138mm) wide by 2.68" (68mm) high panel cutout. (see Mounting Dimensions) To mount the Flow Computer, proceed as follows: Mounting Procedure a. Prepare the panel opening. b. Slide the unit through the panel cutout until the it touches the panel. c. Install the screws (provided) in the mounting bracket and slip the bracket over the rear of the case until it snaps in place. d. Tighten the screws firmly to attach the bezel to the panel. 3 in. lb. of torque must be applied and the bezel must be parallel to the panel. NEMA4X / IP65 Specifications NOTE: To seal to NEMA4X / IP65 specifications, supplied bezel kit must be used and panel cannot flex more than.010". When the optional bezel kit is used, the bezel adaptor must be sealed to the case using an RTV type sealer to maintain NEMA4X / IP65 rating. 2.2 Mounting Diagrams: Standard Mounting ST2 Bezel Kit Mounting ST2 Bezel Adaptor Gasket Mounting Bracket Mounting Bracket Dimensions 5.67 (144) 6.15 (156) 0.28 (7.2) 0.5 (13) 5.43 (138) 3.43 (87) 2.83 (72) Panel Cutout 2.68 (68) (10) Dotted Line Shows Optional Bezel Kit Dimensions are in inches (mm) 8

13 2.2 Mounting Diagrams: (continued) Wall Mount (mounting option W) 9.4 (238) 4.13 (105) 7.3 (184) Security Tag Provisions 2.34 (59.5) 8.4 (213.4) (9.8) 2.33 (59) 0.59 (15) ø 0.75 ø 5 places 4.72 (120) 1.06 (27) 1.10 (28) 1.10 (28) 1.10 (28) 1.10 (28) 0.75 Conduit Knockouts (5 places) 1.10 (28) 1.10 (28) 1.10 (28) 1.10 (28) 7.8 (198) NEMA4 Wall Mount (mounting option N) 9

14 2.2 Mounting Diagrams: (continued) Explosion Proof Mount (mounting option X) (306.3) 9.31 (236.5) (96.8) (166.6) 5.1 (129.5) 1/4" - 20UNC-2B TAP x 5/16" DEEP (6) HOLES CENTERED ON THREE SIDES FOR MOUNTING 3.5 (88.9).28 ±.02 (7.1 ±.5) 3 (76.2) 10.6 (269.2) 1.31 (33.3) 2.13 (54) 1/4" - 20UNC-2B TAP x 5/16" DEEP (6) HOLES CENTERED ON THREE SIDES FOR MOUNTING 1/2"- 14 NPT PLUGS (2 PLACES) 3.5 (88.9) 8.88 (225.5) 3.13 (79.4) 3 (76.2) 3.13 (79.4) 4.63 (117.5) 1.75 (44.5) 2.5 (63.5) 5.09 (129) (258.8) 2.5 (63.5) 3.0 (76.2).5 (12.7) (258.8).5 (12.7).25 (6.35) Explosion Proof Mount (mounting option E) 10

15 3. Applications STEAM MASS 3.1 Steam Mass Measurements: A flowmeter measures the actual volume flow in a steam line. A temperature and/or pressure sensor is installed to measure temperature and/or pressure. Calculations: Density and mass flow are calculated using the steam tables stored in the flow computer. With square law device measurement the actual volume is calculated from the differential pressure, taking into account temperature and pressure compensation. Saturated steam requires either a pressure or temperature measurement with the other variable calculated using the saturated steam curve. Optional steam trap monitoring using Compensation Input 1. Input Variables: Superheated Steam: Flow, temperature and pressure Saturated Steam: Flow, temperature or pressure Output Results: Display Results Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature, Pressure, Density (optional: peak demand, demand last hour, time/date stamp) Analog Output Mass or Volume Flow Rate, Temperature, Pressure Density, Peak Demand, Demand Last Hour Pulse Output Mass or Volume Total Relay Outputs Mass or Volume Flow Rate, Total, Pressure, Temperature, Alarms, Peak Demand, Demand Last Hour Applications: Monitoring mass flow and total of steam. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs. Steam Mass Illustration TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER * Pressure Transmitter Flowmeter Temperature Transmitter * * or Steam Trap Monitor * or Steam Trap Monitor Calculations Mass Flow Mass Flow = volume flow density (T, p) 11

16 STEAM HEAT 3.2 Steam Heat Measurements: A flowmeter measures the actual volume flow in a steam line. A temperature and/or pressure sensor is installed to measure temperature and/or pressure. Calculations: Density, mass flow and heat flow are calculated using the steam tables stored in the flow computer. The heat is defined as the enthalpy of steam under actual conditions with reference to the enthalpy of water at T=0 C. With square law device measurement the actual volume is calculated from the differential pressure, taking into account temperature and pressure compensation. Saturated steam requires either a pressure or temperature measurement with the other variable calculated using the saturated steam curve. Optional steam trap monitoring using compensation input. Input Variables: Superheated Steam: Flow, temperature and pressure Saturated Steam: Flow, temperature or pressure Output Results: Display Results Heat, Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature, Pressure, Density (optional: peak demand, demand last hour, time/date stamp) Analog Output Heat, Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak Demand, Demand Last Hour Pulse Output Heat, Mass or Volume Total Relay Outputs Heat, Mass or Volume Flow Rate, Total, Pressure, Temperature Alarms, Peak Demand, Demand Last Hour Applications: Monitoring heat flow and total heat of steam. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs. Steam Heat Illustration TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER Pressure Transmitter Orifice Plate with DP Transmitter Temperature Transmitter * Pressure Transmitter Flowmeter Temperature Transmitter * * or Steam Trap Monitor * or Steam Trap Monitor Calculations Heat Flow Heat Flow = Volume flow density (T, p) Sp. Enthalpy of steam (T, p) 12

17 STEAM NET HEAT 3.3 Steam Net Heat Measurements: A flowmeter measures the actual volume flow in a steam line. A temperature and a pressure sensor are installed to measure temperature and/or pressure. All measurement are made on the steam side of a heat exchanger. Calculations: Density, mass flow and net heat flow are calculated using the steam tables stored in the flow computer. The net heat is defined as the difference between the heat of the steam and the heat of the condensate. For simplification it is assumed that the condensate (water) has a temperature which corresponds to the temperature of saturated steam at the pressure measured upstream of the heat exchanger. With square law device measurement the actual volume is calculated from the differential pressure, taking into account temperature and pressure compensation. Saturated steam requires either a pressure or temperature measurement with the other variable calculated using the saturated steam curve. Optional steam trap monitoring using compensation input. Input Variables: Superheated Steam: Flow, temperature and pressure Saturated Steam: Flow, temperature or pressure Output Results: Display Results Heat, Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature, Pressure, Density, (optional: peak demand, demand last hour, time/date stamp) Analog Output Heat, Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak Demand, Demand Last Hour Pulse Output Heat, Mass or Volume Total Relay Outputs Heat, Mass or Volume Flow Rate, Total, Pressure, Temperature Alarms, Peak Demand, Demand Last Hour Steam Net Heat Illustration Applications: Monitoring the thermal energy which can be extracted by a heat exchanger taking into account the thermal energy remaining in the returned condensate. For simplification it is assumed that the condensate (water) has a temperature which corresponds to the temperature of saturated steam at the pressure measured upstream of the heat exchanger. Water TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER Steam Calculations Net Heat Flow Pressure Transmitter Flowmeter Temperature Transmitter * or Steam Trap Monitor Net Heat Flow = Volume flow density (T, p) [E D (T, p) E W (T S(p) )] * E D E w T S(p) = Specific enthalpy of steam = Specific enthalpy of water = Calculated condensation temperature (= saturated steam temperature for supply pressure) 13

18 STEAM DELTA HEAT 3.4 Steam Delta Heat Measurements: Measures actual volume flow and pressure of the saturated steam in the supply piping as well as the temperature of the condensate in the downstream piping of a heat exchanger. Calculations: Calculates density, mass flow as well as the delta heat between the saturated steam (supply) and condensation (return) using physical characteristic tables of steam and water stored in the flow computer. With square law device measurement the actual volume is calculated from the differential pressure, taking into account temperature and pressure compensation. The saturated steam temperature in the supply line is calculated from the pressure measured there. Input Variables: Supply: Flow and pressure (saturated steam) Return: Temperature (condensate) Output Results: Display Results Heat, Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature, Pressure, Density (optional: peak demand, demand last hour, time/date stamp) Analog Output Heat, Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak Demand, Demand Last Hour Pulse Output Heat, Mass or Volume Total Relay Outputs Heat, Mass or Volume Flow Rate, Total, Pressure, Temperature Alarms, Peak Demand, Demand Last Hour Applications: Calculate the saturated steam mass flow and the heat extracted by a heat exchanger taking into account the thermal energy remaining in the condensate. Steam Delta Heat Illustration Temperature Transmitter Water TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER Saturated Steam Pressure Transmitter Flowmeter Calculations Delta Heat Flow Net Heat Flow = Volume flow density (p) [E D (p) E W (T)] E D E w = Specific enthalpy of steam = Specific enthalpy of water Note: Assumes a closed system. 14

19 CORRECTED GAS VOLUME 3.5 Corrected Gas Volume Measurements: A flowmeter measures the actual volume flow in a gas line. Temperature and pressure sensors are installed to correct for gas expansion effects. Calculations: Corrected Volume is calculated using the flow, temperature and pressure inputs as well as the gas characteristics stored in the flow computer (see "FLUID DATA" submenu). Use the "OTHER INPUT" submenu to define reference temperature and reference pressure values for standard conditions. Output Results: Display Results Corrected Volume or Actual Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature, Pressure, Density (optional: peak demand, demand last hour, time/date stamp) Analog Output Corrected Volume or Actual Volume Flow Rate, Temperature, Pressure, Density, Peak Demand, Demand Last Hour Pulse Output Corrected Volume or Actual Volume Total Relay Outputs Corrected Volume or Actual Volume Flow Rate, Total, pressure, Temperature Alarms, Peak Demand, Demand Last Hour Applications: Monitoring corrected volume flow and total of any gas. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs. Corrected Gas Volume Illustration TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER Calculations Volume Flow Pressure Transmitter Flowmeter Temperature Transmitter Pulse Input; Average K-Factor Volume Flow = input frequency time scale factor K-Factor Analog Input; Linear Volume Flow = % input Full Scale Flow Corrected Volume Flow P T ref Z ref Corrected Volume Flow = Volume Flow P ref T Z 15

20 GAS MASS 3.6 Gas Mass Measurements: A flowmeter measures the actual volume flow in a gas line. Temperature and pressure sensors are installed to measure temperature and pressure. Calculations: Density and mass flow are calculated using gas characteristics stored in the flow computer. With square law device measurement the actual volume is calculated from the differential pressure, taking into account temperature and pressure compensation. Output Results: Display Results Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature, Pressure, Density (optional: peak demand, demand last hour, time/date stamp) Analog Output Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak Demand, Demand Last Hour Pulse Output Mass or Volume Total Relay Outputs Mass or Volume Flow Rate, Total, Pressure, Temperature, Density Alarms, Peak Demand, Demand Last Hour Applications: Monitoring mass flow and total of gas. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs. Gas Mass Illustration TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER Pressure Transmitter Orifice Plate with DP Transmitter Temperature Transmitter Pressure Transmitter Flowmeter Temperature Transmitter Calculations Mass Flow P T ref Z ref Mass Flow = Actual Volume Flow ρ ref P ref T Z ρ ref T ref P ref Z ref = Reference density = Reference temperature = Reference pressure = Reference Z-factor 16

21 GAS COMBUSTION HEAT 3.7 Gas Combustion Heat Measurements: A flowmeter measures the actual volume flow in a gas line. Temperature and pressure sensors are installed to measure temperature and pressure. Calculations: Density, mass flow and combustion heat are calculated using gas characteristics stored in the flow computer. With square law device measurement the actual volume is calculated from the differential pressure, taking into account temperature and pressure compensation. Output Results: Display Results Heat, Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature, Pressure, Density (optional: peak demand, demand last hour, time/date stamp) Analog Output Heat, Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak Demand, Demand Last Hour Pulse Output Heat, Mass or Volume Total Relay Outputs Heat, Mass or Volume Flow Rate, Total, Pressure, Temperature Alarms, Peak Demand, Demand Last Hour Applications: Calculate the energy released by combustion of gaseous fuels. Gas Combustion Heat TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER Pressure Transmitter Flowmeter Temperature Transmitter Calculations Combustion Heat Flow P T ref Z ref Combustion Energy = C ρ ref Q P ref T Z C ρ ref Q = Specific combustion heat = Reference density = Volume flow 17

22 Corrected Liquid Volume 3.8 Corrected Liquid Volume Measurements: A flowmeter measures the actual volume flow in a liquid line. A temperature sensor is installed to correct for liquid thermal expansion. A pressure sensor can be installed to monitor pressure. Pressure measurement does not affect the calculation. Calculations: Corrected Volume is calculated using the flow and temperature inputs as well as the thermal expansion coefficient stored in the flow computer (see "FLUID DATA" submenu). Use the "OTHER INPUT" submenu to define reference temperature and density values for standard conditions. Output Results: Display Results Corrected Volume and Actual Volume Flow Rate, Resettable Total, Non- Resettable Total, Temperature, Pressure, Density (optional: peak demand, demand last hour, time/date stamp) Analog Output Corrected Volume and Actual Volume Flow Rate, Temperature, Pressure, Density, Peak Demand, Demand Last Hour Pulse Output Corrected Volume and Actual Volume Total Relay Outputs Corrected Volume and Actual Volume Flow Rate, Total, Pressure, Temperature Alarms, Peak Demand, Demand Last Hour Corrected Liquid Volume Illustration Applications: Monitoring corrected volume flow and total of any liquid. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs. TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER Optional Pressure Transmitter Flowmeter Temperature Transmitter Calculations Volume Flow Pulse Input; Average K-Factor Volume Flow = input frequency time scale factor K-Factor Analog Input; Linear Volume Flow = % input Full Scale Flow Corrected Volume Flow Corrected Volume Flow = vol. flow (1 - α (Tf-Tref)) 2 α = Thermal expansion coefficient

23 Liquid Mass 3.9 Liquid Mass Measurements: Actual volume flow is measured by the flow element (DP transmitter, Flowmeter). Temperature is measured by the temperature transmitter. A pressure transmitter can be used to monitor pressure. Pressure measurement does not affect the calculation. A density transmitter may be used in place of a temperature transmitter for direct density measurement. Calculations: The density and mass flow are calculated using the reference density and the thermal expansion coefficient of the liquid (see "FLUID DATA" submenu) Output Results: Display Results Mass or Volume Flow Rate, Resettable Total, Non-Resettable Total, Temperature, Pressure, Density (optional: peak demand, demand last hour, time/date stamp) Analog Output Mass or Volume Flow Rate, Temperature, Pressure, Density, Peak Demand, Demand Last Hour Pulse Output Mass or Volume Total Relay Outputs Mass or Volume Flow Rate, Total, Temperature, Pressure, Density Alarms, Peak Demand, Demand Last Hour Applications: Monitoring mass flow and total of any liquid. Flow alarms are provided via relays and datalogging is available via analog (4-20mA) and serial outputs. Liquid Mass Illustration TOTAL 1 RATE 2 PRE 1 3 TEMP 4 PRINT 5 CLEAR MENU GRAND 6 SCROLL 7 PRE 2 8 DENS 9 TIME 0 HELP ENTER Optional Pressure Flowmeter Transmitter T 1 Temperature Transmitter NOTE: A density transmitter may be used for direct density measurement. Calculations Volume Flow As calculated in section 3.8 Mass Flow Mass Flow = volume flow (1-a (T 1 -T ref )) 2 ref. density α = Thermal expansion coefficient